JP2011137563A - Heat exchanger for intercooler - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve the strength of a resin component in comparison with conventional types, in a heat exchanger for an intercooler constituting the resin component made of a glass-fiber reinforced resin material. <P>SOLUTION: Glass fiber (B) having an average value of irregular shape aspect ratio of 1 or more, is used, when the irregular shape aspect ratio is the ratio of a long diameter to a short diameter, on a cross-sectional face of the glass fiber, and a tank body 122 of the intercooler 100 is made of a resin composition including 1-250 pts.wt.of glass fiber to 100 pts.wt. of thermoplastic resin. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a heat exchanger for an intercooler.

  As an intercooler heat exchanger, one having a resin part such as a resin tank is manufactured and sold. This resin-made part is comprised with the resin material (glass fiber reinforced resin material) reinforced with glass fiber.

  As described above, the strength of the resin material can be improved by adding glass fiber to the resin material, but there is a limit to the improvement of the strength.

  Therefore, the inventor of the present application investigated the strength of the conventional glass fiber reinforced resin material in order to further improve the strength of the glass fiber reinforced resin material, and compared with other directions in the direction perpendicular to the orientation direction of the glass fiber. And it turned out that the effect of the strength improvement of the resin material by addition of glass fiber is small. Incidentally, when a resin part having a desired shape is manufactured by flowing molten resin through a mold, glass fibers are oriented in the resin flow direction, that is, the longitudinal direction of the glass fibers is parallel to the resin flow direction.

  For this reason, in order to further improve the strength of the glass fiber reinforced resin material, it is necessary to improve the strength in the direction perpendicular to the orientation direction of the glass fibers.

  In view of the above points, an object of the present invention is to improve the strength of a resin part in an intercooler heat exchanger including a resin part made of a glass fiber reinforced resin material.

  In order to achieve the above object, in the invention according to claim 1, in the heat exchanger for the intercooler, if the ratio of the major axis to the minor axis in the cross section of the glass fiber is an irregular ratio, the resin part has an irregular ratio. It is characterized by being comprised with the resin composition formed by containing 1 to 250 weight part of glass fibers (B) whose average value is larger than 1 with respect to 100 weight part of thermoplastic resins (A).

  Conventionally, a glass fiber having an irregularity ratio of 1 was used, whereas in the present invention, a glass fiber having an irregularity ratio larger than 1 is used, so that the glass fiber in a direction perpendicular to the orientation direction of the glass fiber is used. The strength can be improved as compared with the conventional case, and the strength of the resin part can be improved as compared with the conventional case.

  By the way, according to the test results of the present inventors, in a test piece made of a thermoplastic resin to which glass fibers are added, when glass fibers having a deformed ratio larger than 1 are used, the added amount of glass fibers is the same and the deformed ratio It is known that the strength in the direction perpendicular to the orientation direction of the glass fiber is improved as compared with the case where the glass fiber of No. 1 is used.

  In addition, the addition amount of glass fiber should just be a range from which a desired shape is obtained with a resin composition. Further, the average value of the deformed ratio is a value including an error of ± 0.3.

  In the invention described in claim 2, the glass fiber (B) is characterized in that the average value of the deformation ratio is 1.5-6. In a heat exchanger that requires high strength, it is better that the deformation ratio is large. However, considering the practical use of the heat exchanger, it is preferable to use glass fibers having a deformation ratio in such a range.

  The invention according to claim 3 is characterized in that the thermoplastic resin (A) contains 30 to 100 parts by weight of the polyamide (a1) in 100 parts by weight of the total amount of the thermoplastic resin (A). .

  Thus, it is preferable to mainly use polyamide as the thermoplastic resin (A). Furthermore, if a mixed resin of polyamide and a thermoplastic resin other than polyamide is used, characteristics that are difficult to develop with polyamide alone can be imparted to resin parts.

In the invention according to claim 4, the polyamide (a1) has a dicarboxylic acid unit (i) and a diamine unit (ii),
The dicarboxylic acid unit (i) contains 40 to 100 mol% of terephthalic acid units, 0 to 40 mol% of aromatic dicarboxylic acid units other than terephthalic acid, and 0 to 60 mol% of aliphatic dicarboxylic acid units. So that the total of 100 mol%,
The diamine unit (ii) is characterized by containing 60 to 100 mol% of an aliphatic diamine unit having 4 to 18 carbon atoms.

  Here, the resin parts of the heat exchanger for the intercooler are required to have hydrolysis resistance because they are mounted on the vehicle, and a high-temperature and high-pressure heat medium flows inside the heat exchanger. In addition, when an acidic heat medium flows through the heat exchanger, acid resistance is required.

  Therefore, by using the polyamide according to claim 4 as a thermoplastic resin, a resin part excellent in heat resistance, pressure resistance, hydrolysis resistance and acid resistance can be obtained.

  The invention according to claim 5 is characterized in that both 1,9-nonanediamine unit and 2-methyl-1,8-octanediamine unit are used as the aliphatic diamine unit having 4 to 18 carbon atoms. Yes.

  Here, the heat exchanger for the intercooler has an acidic heat medium flowing therein, so that the acid resistance is required for the resin parts, particularly as the aliphatic diamine unit, according to claim 5. By using one, a resin part having excellent heat resistance and acid resistance can be obtained.

  The invention according to claim 6 is characterized in that the polyamide (a1) having an intrinsic viscosity of 0.4 to 3.0 dl / g measured at 30 ° C. in concentrated sulfuric acid is used. .

  Here, when the intrinsic viscosity is lower than 0.4 dl / g, the heat resistance and strength of the polyamide according to claims 4 and 5 are lowered, and when it is higher than 3.0 dl / g, the moldability is lowered. is there. Therefore, by using the polyamide (a1) having the intrinsic viscosity according to claim 6, a resin part having excellent heat resistance and pressure resistance can be obtained, and productivity of the resin part can be increased.

  In the first and second aspects of the invention, polyphenylene sulfide (a2) can be used as the thermoplastic resin (A) as in the seventh aspect of the invention. As in the invention, the modified resin (a3) can be used.

  This modified resin (a3) is a heat modified with at least one resin selected from the group consisting of polyolefin resins, polyester resins, polythioether resins, polyacrylonitrile resins, fluorine resins, and styrene elastomers. It means a plastic resin. Examples of the modified resin include those obtained by modifying polyphenylene sulfide with a polyolefin resin to improve toughness.

  In the present specification, “modified” means that the thermoplastic resin serving as the base material and other components are chemically bonded.

  Thus, the pressure resistance of resin-made components can be improved by using the modified resin in which the toughness of the base material is improved.

  Further, as in the ninth aspect of the invention, the tank body (122) of the header tank (120) can be composed of the resin composition described above.

  Further, as in the invention described in claim 10, the above-mentioned heat exchanger is suitable for use as a heat exchanger for an intercooler that cools a mixed gas of combustion air and exhaust gas.

  Moreover, like the invention of Claim 11, it is preferable that a resin composition contains 70-150 weight part of glass fibers (B) with respect to 100 weight part of thermoplastic resins (A).

It is a front view of the intercooler in a 1st embodiment of the present invention. It is a cross-sectional view of the glass fiber used in 1st Embodiment of this invention.

(First embodiment)
In FIG. 1, the front view of the intercooler in this embodiment is shown.

  The intercooler 100 is used in a supercharging system to cool combustion air (intake air) sucked into an internal combustion engine by heat exchange with cooling air. Specifically, the intercooler 100 is shown in FIG. As described above, a plurality of tubes 111 and two header tanks 120 are provided.

  The tube 111 has a flat shape, and intake air as fluid flows through the inside of the tube 111. A plurality of tubes 111 are arranged side by side in a direction orthogonal to the longitudinal direction. A corrugated outer fin 112 is joined to the outer surface of the tube 111.

  The outer fin 112 promotes heat exchange between the cooling air flowing around the tube 111 and the intake air flowing inside the tube 111. The outer fin 112 and the tube 111 are made of aluminum, and thereby constitute a substantially rectangular cooling core portion (hereinafter abbreviated as a core) 110 for cooling the intake air.

  Further, similarly to the outer fin, a wavy inner fin (not shown) for promoting heat exchange is disposed inside the tube 111.

  The header tanks 120 are disposed on both ends in the longitudinal direction of the tube 111, extend in a direction perpendicular to the longitudinal direction of the tube 111, and communicate with the plurality of tubes 111. One of the header tanks 120 distributes and supplies intake air pumped from a supercharger (not shown) to each tube 111, and the other collects and collects intake air flowing out from each tube 111 and sends it to the internal combustion engine.

  The header tank 120 has an aluminum core plate 121 to which the tubes 111 are brazed and a tank main body 122 as a resin part that constitutes a tank internal space together with the core plate 121. The tank body 122 is caulked and fixed to the core plate 121 via a packing (not shown). The tank body 122 is made of a glass fiber reinforced resin material reinforced with glass fibers, and details of specific materials will be described later.

  Further, in the end portion of the core 110 where the header tank 120 is not provided, as shown in FIG. 2, an aluminum insert (reinforcement) that extends substantially parallel to the tube 111 and reinforces the core portion 110. Plate) 130 is provided. The surface of the insert 130 on the core 110 side is brazed to the outer fin 112, and both end portions in the longitudinal direction are brazed to the header tank 120 (core plate 121).

  By the way, the intercooler 100 is a heat exchanger that cools the air whose temperature has been increased by compression of the supercharger. Therefore, the tank body 122 has a high-temperature and high-pressure characteristic (heat resistance) that does not break even when high-temperature and high-pressure air flows. , Pressure resistance) is required.

  Further, as an example of use of the intercooler 100, there is a case where a mixed gas of intake air and exhaust gas is cooled as used in a so-called LPL (low pressure loop) system in addition to being used in a general supercharging system. is there.

  Incidentally, the LPL system is a kind of an exhaust gas recirculation (EGR) system that recirculates exhaust gas to the internal combustion engine, and is branched from the downstream of the turbocharger turbine in the exhaust system of the internal combustion engine. In this intake system, exhaust gas is circulated upstream of the compressor of the supercharger.

  In this case, the mixed gas flowing inside the intercooler 100 is at a higher temperature and pressure than the intake air of a general supercharging system, and the exhaust gas containing NOx and SOx causes the inside of the header tank 120 to become a strong acid environment. The main body 122 is required to have high temperature and high pressure characteristics and acid resistance.

  It is known that the intercooler 100 is generally required to have hydrolysis resistance and calcium chloride resistance. The reason why the calcium chloride resistance is required is that calcium chloride adheres to the outer surface of the intercooler 100 because calcium chloride is distributed as a snow melting agent in snowfall areas.

  Therefore, the tank main body 122 of the present embodiment is a glass fiber having an average value of the deformation ratio larger than 1 with respect to the thermoplastic resin (A) so as to satisfy the performance (specification) required for the above-described intercooler. It is comprised with the resin composition to which (B) was added.

  Here, the profile ratio of the glass fiber will be described. 2A to 2C are cross-sectional views of glass fibers used in the present embodiment. First, in this embodiment, a glass fiber having an elongated cross-sectional shape is used. Examples of the cross-sectional shape include eyebrows, ellipses, rectangles, and the like as shown in FIGS. 2 (a), 2 (b), and 2 (c). And, as shown in FIGS. 2 (a) to (c), the profile ratio means that the longest width in the cross section of the glass fiber is the long diameter and the longest width in the direction perpendicular to the long diameter direction is the short diameter. The ratio of the major axis to the minor axis (major axis / minor axis).

  The glass fiber having an average deformed ratio value greater than 1 is used in comparison with the case where glass fibers having the same added amount of glass fiber and having an average deformed ratio value of 1 are used. This is because the strength in the direction perpendicular to the direction can be improved, and the pressure resistance strength of the tank body 122 can be improved.

  The average value of the deformed ratios only needs to be in the range of 1.2 to 6. As can be seen from the examples described later, in order to satisfy the specifications of the high temperature and high pressure characteristics required for the intercooler, 1.5 or more It is preferable that it is 2 or more. On the other hand, from the viewpoint of ease of production of the glass fiber, the average value of the deformation ratio is preferably 6 or less, more preferably 4 or less. When the profile ratio exceeds 6, it becomes relatively difficult to produce the glass fiber, and when it is 6 or less, the production is relatively easy, and when it is 4 or less, the production is easier when the following examples are applicable. Because. In addition, the average value of the deformed ratio here is a value including an error of ± 0.3, as in an example described later.

  The fiber length of glass fiber should just be 1-10 mm. Further, the glass fiber content can be set within a range of 1 to 250 parts by weight with respect to 100 parts by weight of the thermoplastic resin (A) so as to satisfy the specifications of the high temperature and high pressure characteristics required for the intercooler. 70 to 150 parts by weight, and more preferably 70 to 90 parts by weight as can be seen from the examples described later.

  As the thermoplastic resin (A) constituting the tank body 122, polyamide (a1), polyphenylene sulfide = PPS (a2), or modified resin (a3) can be used.

  When the polyamide (a1) is used as the thermoplastic resin (A), 30 to 100 parts by weight of the polyamide (a1) is used in 100 parts by weight of the total amount of the thermoplastic resin (A). That is, as the thermoplastic resin (A), only the polyamide (a1) is used, or the polyamide (a1) and a thermoplastic resin other than the PPS (a2), the modified resins (a3), and (a1) to (a3) described later The mixed resin can be used. If a mixed resin is used, the tank body 122 can be imparted with characteristics that are difficult to express with only polyamide.

  The polyamide (a1) used in the present embodiment has a dicarboxylic acid unit (i) and a diamine unit (ii). The ratio of the dicarboxylic acid unit (i) and the diamine unit (ii) is 100 mol%: 100 mol%. Furthermore, this dicarboxylic acid unit (i) is 40-100 mol% of terephthalic acid units, 0-40 mol% of aromatic dicarboxylic acid units other than terephthalic acid, 0-60 mol% of aliphatic dicarboxylic acid units, So that their total is 100 mol%. On the other hand, the diamine unit (ii) contains 60 to 100 mol% of an aliphatic diamine unit having 4 to 18 carbon atoms.

  That is, as the dicarboxylic acid unit (i), only terephthalic acid units are used, two types of terephthalic acid units and aromatic dicarboxylic acid units other than terephthalic acid are used, or terephthalic acid units and aliphatic dicarboxylic acid units 2 are used. The kind can be used, or three kinds of terephthalic acid units, aromatic dicarboxylic acid units other than terephthalic acid, and aliphatic dicarboxylic acid units can be used.

  The reason why 40 to 100 mol% of terephthalic acid units are used as the dicarboxylic acid unit (i) is to secure heat resistance necessary for the intercooler, and when the terephthalic acid unit is less than 40 mol%, it is necessary for the intercooler. This is because heat resistance may not be obtained. The terephthalic acid unit is included in the aromatic dicarboxylic acid unit.

  Examples of aromatic dicarboxylic acid units other than terephthalic acid include isophthalic acid, 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, and 1,4-phenylenedioxydiacetic acid. 1,3-phenylenedioxydiacetic acid, diphenic acid, 4,4′-oxydibenzoic acid, diphenylmethane-4,4′-dicarboxylic acid, diphenylsulfone-4,4′-dicarboxylic acid, 4,4′-biphenyl And dicarboxylic acid.

  Examples of the aliphatic dicarboxylic acid unit include adipic acid, malonic acid, dimethylmalonic acid, succinic acid, glutaric acid, 2-methyladipic acid, trimethyladipic acid, pimelic acid, 2,2-dimethylglutaric acid, 3, 3 -Diethylsuccinic acid, azelaic acid, sebacic acid, suberic acid and the like.

  The reason why the aliphatic diamine unit having 4 to 18 carbon atoms is used as the diamine unit (ii) is to ensure hydrolysis resistance, heat resistance and acid resistance necessary for the intercooler. Incidentally, an aliphatic diamine unit having a carbon number of less than 4 has low hydrolysis resistance, and an aliphatic diamine unit having a carbon number of greater than 18 may have low heat resistance.

  Further, as the diamine unit (ii), the aliphatic diamine unit having 4 to 18 carbon atoms is contained in an amount of 60 mol% or more. When the content is less than 60 mol%, the aliphatic diamine unit having 4 to 18 carbon atoms. This is because the hydrolysis resistance and heat resistance are not sufficiently exhibited.

  Examples of aliphatic diamine units having 4 to 18 carbon atoms include hexamethylenediamine (carbon number 6), 1,9-nonanediamine (carbon number 9), 2-methyl-1,8-octanediamine (carbon number 9), tetra Examples include methylenediamine (carbon number 4) and methylpentanediamine (carbon number 6).

  Among these, from the viewpoint of obtaining high acid resistance, it is preferable to use a 1,9-nonanediamine unit and a 2-methyl-1,8-octanediamine unit alone or to use both of them.

  The polyamide (a1) used in the present embodiment has a high molecular weight in order to ensure the heat resistance and pressure resistance required for the tank body of the intercooler. However, if the molecular weight is too high, the fluidity will be low, the moldability will be poor, the molding of the tank body will be difficult or the productivity will be lowered, so the molecular weight should be within the range where the tank body can be produced well. It is set.

  Specifically, the polyamide (a1) used in this embodiment preferably has an intrinsic viscosity [η] measured at 30 ° C. in concentrated sulfuric acid of 0.4 to 3.0 dl / g. Here, the intrinsic viscosity is higher as the molecular weight is higher. When the intrinsic viscosity [η] is lower than 0.4 dl / g, the heat resistance and pressure resistance are lowered, and when it is higher than 3.0 dl / g, the moldability may be deteriorated. Therefore, by using the polyamide (a1) having an intrinsic viscosity [η] in such a range, a tank body excellent in heat resistance and pressure strength can be obtained, and productivity of the tank body can be increased. The intrinsic viscosity [η] is more preferably 0.6 to 1.8 dl / g from the viewpoints of heat resistance, pressure strength, and productivity.

  Moreover, the above-mentioned polyamide (a1) can be produced using any method known as a method for producing crystalline polyamide. For example, it can be produced by a solution polymerization method or an interfacial polymerization method using acid chloride and diamine as raw materials, a melt polymerization method using dicarboxylic acid and diamine as raw materials, a solid phase polymerization method, a melt extruder polymerization method, or the like.

  More specifically, for example, a diamine, a dicarboxylic acid, a catalyst and, if necessary, an end-capping agent are added all at once to produce a nylon salt, followed by heat polymerization at a temperature of 200 to 250 ° C. The above-mentioned polyamide (a1) is prepared by preparing a prepolymer having an intrinsic viscosity [η] at 30 ° C. in concentrated sulfuric acid of 0.1 to 0.6 dl / g and further performing solid-phase polymerization or polymerization using a melt extruder. ) Is obtained.

  When the intrinsic viscosity [η] of the prepolymer is in the range of 0.1 to 0.6 dl / g, there is little shift in the molar balance of carboxyl groups and amino groups and a decrease in polymerization rate in the post-polymerization stage, and the molecular weight A polyamide having a small distribution and excellent in various physical properties and moldability can be obtained. When the final stage of the polymerization is carried out by solid phase polymerization, it is preferably carried out under reduced pressure or under an inert gas flow. If the polymerization temperature is in the range of 200 to 280 ° C., the polymerization rate is large and the productivity is excellent Coloring and gelation can be effectively suppressed. The polymerization temperature when the final stage of the polymerization is carried out with a melt extruder is preferably 370 ° C. or lower. When polymerized under such conditions, polyamide is hardly decomposed and a polyamide having no deterioration is obtained.

  Moreover, PPS (a2) can also be used as a thermoplastic resin (A). PPS is well known as a super engineering plastic excellent in heat resistance, mechanical strength, acid resistance, and the like, and can be obtained by synthesis of paradichlorobenzene and sodium sulfide.

  Moreover, a modified resin (a3) can also be used as a thermoplastic resin (A). This modified resin (a3) is a heat modified with at least one resin selected from the group consisting of polyolefin resins, polyester resins, polythioether resins, polyacrylonitrile resins, fluorine resins, and styrene elastomers. It means a plastic resin.

  This modified resin (a3) can be obtained by adding a resin for modification to the resin as a base material and reacting it. At this time, an unsaturated compound having at least one of a carboxyl group and an acid anhydride group is suitably used as the resin for modification. For example, a polymer obtained by polymerizing a resin for modification and an unsaturated compound may be added to the substrate, or a resin for modification and the unsaturated compound may be added to the substrate at the same time.

  Specifically, as the modified resin (a3), one obtained by modifying PPS as a base material to improve toughness can be used. Since PPS has low toughness as compared with the above-mentioned polyamide (a1), it is preferable to use PPS having improved toughness by enhancing elasticity with a polyolefin resin or the like.

  Thus, the pressure resistance of a tank main body can be improved by using the modified resin whose toughness of the base material is improved. In addition to polyamide and PPS, the base material is a thermoplastic resin that is excellent in heat resistance, mechanical strength, acid resistance, etc., and has lower toughness than the above-mentioned polyamide (a1). May be.

  Next, the manufacturing method of the intercooler 100 of this embodiment is demonstrated.

(Molding the tank body)
A resin composition in which the above-described thermoplastic resin (A), glass fiber (B) and various additives are blended is prepared, and the tank body 122 is molded by melting and introducing the resin composition into a mold. .

  As a blending method at this time, for example, a method of adding components such as glass fiber (B) during the synthesis of the thermoplastic resin (A), or a component such as thermoplastic resin (A) and glass fiber (B) is dried. A blending method, a melt kneading method using an extruder, or the like can be employed. As a molding method, a known molding method such as injection molding can be employed.

(Manufacture of intercooler)
A resin-molded tank body 122, an aluminum tube 111, a core plate 121, and the like are prepared.

  First, on a work table such as a surface plate, the cores 110 are assembled by stacking and assembling the tubes 111, fins 112, and inserts 130 in the horizontal direction as shown in FIG. 1 (core assembling step).

  Next, after the core plate 121 is assembled to the core 110 (including the insert 130) (tank assembly step), the width direction W (longitudinal direction) of the insert 130 is maintained while maintaining the state assembled by a jig such as a wire. And brazing by heating in a furnace so that the direction perpendicular to the vertical direction coincides with the vertical direction (brazing step).

  After completion of the brazing process, the tank body 122 is fixed to the core plate 121 by caulking (caulking process), and then predetermined inspections such as leakage (brazing defects, caulking defects, etc.) inspection and dimensional inspection are performed, and the intercooler Complete the production.

  As described above, according to the present embodiment, the tank body 122 is composed of the above-described resin composition, so that the heat resistance, pressure resistance, hydrolysis resistance, acid resistance, acid resistance required for the intercooler, A tank body 122 having calcium chloride resistance can be provided.

(Other embodiments)
(1) The thermoplastic resin (A) may be a thermoplastic resin other than the above-mentioned polyamide (a1), PPS (a2), and modified resin (a3). Even when other thermoplastic resins are used, the same effects as those of the above-described embodiment can be obtained by using glass fibers having a cross-sectional deformation ratio larger than 1.

  (2) In the above-described embodiment, the case where the resin component is the tank main body has been described. For example, a portion other than the tank main body such as the core plate may be configured with the resin composition of the above-described embodiment. .

  (3) In the above-described embodiment, the present invention is applied to a heat exchanger for an intercooler. However, the present invention may be applied to a heat exchanger other than an intercooler. The heat exchanger of the present invention is a heat exchanger used in a vehicle cooling system, for example, a heat exchanger for a radiator that cools engine coolant as a fluid, or an EGR that cools exhaust gas recirculated to an internal combustion engine. It can be applied to heat exchangers.

  In this case, the glass fiber content may be in a range where a desired shape can be obtained by the resin composition, and may be in the range of 1 to 250 parts by weight with respect to 100 parts by weight of the thermoplastic resin (A). If the content of the glass fiber is the same, using a glass fiber having a cross-sectional deformation ratio larger than 1 makes it perpendicular to the orientation direction compared to using a glass fiber having a cross-sectional deformation ratio of 1. The strength in any direction can be improved.

  Hereinafter, the Example and comparative example of the heat exchanger for intercoolers are described. Tables 1 and 2 show the composition and characteristic evaluation results of the resin compositions in Examples 1 to 11 and Comparative Examples 1 and 2.

実施例１〜１１および比較例１、２では、表１、２に記載の樹脂組成物を用いて、タンク本体を成形し、インタークーラを製造した。なお、タンク本体の形状は、一般的な量産形状とした。また、ガラス繊維としては、以下のものを用いた。
・異形比の平均値が１のガラス繊維：日東紡績（株）製「ＣＳ−３Ｊ−２５６」、異形比１．０±０．３、横断面形状は円形、直径１１μｍ（平均値）、繊維長さ３ｍｍ（平均値）
・異形比の平均値が２のガラス繊維：日東紡績（株）製「ＣＳＨ ３ＰＡ−８７０」、異形比２．０±０．３、横断面形状はまゆ形、長径２０μｍ（平均値）、繊維長さ３ｍｍ（平均値）
・異形比４のガラス繊維：日東紡績（株）製「ＣＳＨ ３ＰＡ−８２０」、異形比４．０±０．３、横断面形状は長方形、長径２８μｍ（平均値）、繊維長さ３ｍｍ（平均値）
そして、インタークーラのタンク本体における高温高圧特性、耐酸性、塩化カルシウム特性について、下記の方法によって評価した。

In Examples 1 to 11 and Comparative Examples 1 and 2, tank bodies were molded using the resin compositions described in Tables 1 and 2 to produce an intercooler. The shape of the tank body was a general mass production shape. Moreover, the following were used as glass fiber.
・ Glass fiber having an average ratio of 1 in the shape ratio: “CS-3J-256” manufactured by Nitto Boseki Co., Ltd., profile ratio 1.0 ± 0.3, circular in cross section, diameter 11 μm (average value), fiber Length 3mm (average value)
・ Glass fiber with average value of deformed ratio: 2 “CSH 3PA-870” manufactured by Nitto Boseki Co., Ltd., deformed ratio of 2.0 ± 0.3, cross-sectional shape of eyebrows, major axis 20 μm (average value), fiber Length 3mm (average value)
・ Glass fiber having an irregularity ratio of 4: “CSH 3PA-820” manufactured by Nitto Boseki Co., Ltd. value)
And the high temperature / high pressure characteristic, acid resistance, and calcium chloride characteristic in the tank body of the intercooler were evaluated by the following methods.

  The high-temperature and high-pressure characteristics repeat the operation of applying a pressure of 200 kPa at 200 ° C. for 1.5 seconds inside the intercooler and then returning to the normal pressure for 1.5 seconds, and the intercooler is cracked and a pressure of 200 kPa is applied. It was evaluated by the number of times until it was not possible. If the number of measurements satisfies the specifications required for the intercooler (100,000 times or more), it will be judged as ◯, and if it will satisfy the specifications but will be the same as the reference value, it will be judged as △. It was determined.

  The acid resistance was evaluated from the strength retention by molding an ISO dumbbell piece with the same resin composition as that constituting the tank body and immersing the ISO dumbbell piece in sulfuric acid having a concentration of 2000 ppm at 90 ° C. for 168 hours. In addition, as the strength of the ISO dumbbell piece, the tensile strength was measured in accordance with ISO 527-1 and 2. If the strength retention satisfies the specifications required for the intercooler (50% or more), it was judged as “good”, and if it did not satisfy the specifications, it was judged as “poor”.

Resistance to calcium chloride was evaluated by the presence or absence of cracking after applying an internal pressure of 200 kPa in an 80 ° C., 30% RH environment after applying a 35 wt% calcium chloride aqueous solution to the surface of the intercooler. . If there was no crack, it was judged as “good”.
(Example 1, Comparative Example 1)
In both Example 1 and Comparative Example 1, polyamide (a1) was used as the thermoplastic resin (A). Polyamide (a1) comprises dicarboxylic acid unit (i) composed of 50 mol% terephthalic acid and 50 mol% adipic acid which is an aliphatic dicarboxylic acid unit, and diamine unit (ii) composed of 100 mol% hexamethylenediamine. And synthesized. The intrinsic viscosity [η] measured at 30 ° C. in the concentrated sulfuric acid of polyamide was 1.2 dl / g.

  And as a glass fiber (B), in Example 1, 82 weight part of the deformation ratio of 2 was used, whereas in Comparative Example 1, 82 weight part of the deformation ratio of 1 was used.

As shown in Table 1, with respect to the results of the characteristic evaluation, in Comparative Example 1 in which the profile ratio was 1, the high-temperature and high-pressure characteristics and acid resistance did not satisfy the specifications, whereas the profile ratio was 2. In Example 1, the high-temperature and high-pressure characteristics, acid resistance, and calcium chloride resistance satisfied the specifications.
(Examples 2 to 4)
In both Examples 2 to 4, 100 mol% of terephthalic acid was used as the dicarboxylic acid unit (i) of the polyamide (a1), and 80 mol% of 1,9-nonanediamine and 2-methyl-1,2 were used as the diamine unit (ii). 20-mol% 8-octanediamine was used.

  And as a glass fiber (B), in Example 2, the one with an irregularity ratio of 2 is used, in Example 3, the one with an irregularity ratio of 4 is used, and in Example 4, the one with an irregularity ratio of 1.5 is used. used. Others are the same as in the first embodiment.

About the result of characteristic evaluation, as shown in Table 1, in all of Examples 2 to 4, the high-temperature and high-pressure characteristics, acid resistance, and calcium chloride resistance all satisfied the specifications. Therefore, in Comparative Example 1 in which the profile ratio is 1, the high-temperature and high-pressure characteristics and acid resistance did not satisfy the specifications, so it can be said that the profile ratio is preferably 1.5 or more. However, in Example 4 where the deformation ratio is 1.5, the result of the high-temperature and high-pressure characteristics was about 100,000 times, and the high-temperature and high-pressure characteristics were lower than those in Examples 2 and 3, so the deformation ratio was 2 or more. It can be said that it is more preferable. Further, in Example 3 in which the profile ratio was 4, the result of the high temperature and high pressure characteristics was about 200,000 times, and the high temperature and high pressure characteristics were higher than those in Examples 2 and 4. Therefore, the profile ratio was 4 It can be said that it is more preferable.
(Examples 5 and 6)
In Examples 5 and 6, the amount of glass fiber (B) added to Example 2 was changed to 70 and 90 parts by weight with respect to 100 parts by weight of the thermoplastic resin (A). Is the same as in Example 2.

Regarding the results of the characteristic evaluation, as shown in Table 1, the high-temperature and high-pressure characteristics, acid resistance and calcium chloride resistance characteristics all satisfied the specifications. From Examples 2, 5, and 6, the amount of glass fiber (B) added is in the range of 70 to 90 parts by weight with respect to 100 parts by weight of the thermoplastic resin (A), and each characteristic of the tank body satisfies the required specifications. I understand that.
(Example 7)
As Example 1, except that 20 mol% of hexamethylenediamine and 80 mol% of tetramethylenediamine are used as the diamine unit (ii) of the polyamide (a1). As shown in Table 2, the high-temperature and high-pressure characteristics, acid resistance, and calcium chloride resistance characteristics all satisfied the specifications.
(Example 8)
Example except that 100 mol% of terephthalic acid was used as the dicarboxylic acid unit (i) of the polyamide (a1) and 50 mol% of hexamethylenediamine and 50 mol% of methylpentanediamine were used as the diamine unit (ii). Same as 1. As shown in Table 2, the high-temperature and high-pressure characteristics, acid resistance, and calcium chloride resistance characteristics all satisfied the specifications.
Example 9
As the dicarboxylic acid unit (i) of the polyamide (a1), 50 mol% of terephthalic acid, 30 mol% of isophthalic acid which is an aromatic dicarboxylic acid unit other than terephthalic acid, and 20 mol% of adipic acid which is an aliphatic dicarboxylic acid unit. Example 2 is the same as Example 2 except that is used. As shown in Table 2, the high-temperature and high-pressure characteristics, acid resistance, and calcium chloride resistance characteristics all satisfied the specifications.
(Example 10, comparative example 2)
In both Example 10 and Comparative Example 2, PPS (a2) was used as the thermoplastic resin (A). Further, as the glass fiber (B), 82 parts by weight of the one with an irregularity ratio of 4 was used in Example 10, and 82 parts by weight of the one with an irregularity ratio of 1 was used in Comparative Example 2. PPS was obtained by subjecting equimolar amounts of paradichlorobenzene (p-DCB) and sodium sulfide (Na ₂ S) to a polycondensation reaction in N-methyl-2-pyrrolidone at 280 ° C. The intrinsic viscosity [η] measured at 30 ° C. in concentrated sulfuric acid of PPS was 1.4 dl / g.

With respect to the results of the characteristic evaluation, as shown in Table 2, in Comparative Example 2 in which the profile ratio was 1, the high-temperature and high-pressure characteristics did not satisfy the specifications, whereas in Example 10 in which the profile ratio was 4, The high-temperature and high-pressure characteristics, acid resistance, and calcium chloride resistance all met the specifications.
(Example 11)
The modified resin (a3) was used as the thermoplastic resin (A). Specifically, PPS modified with 20 parts by weight of polyolefin resin was used with respect to 100 parts by weight of PPS. A modified PPS was obtained by kneading a polyolefin resin and an ethylene-based tuffmer manufactured by Mitsui Chemicals, Inc. with respect to PPS. At this time, 30 parts by weight of ethylene-based toughmer was used with respect to 100 parts by weight of PPS. Others are the same as in Example 10.

  As shown in Table 2, the results of the characteristic evaluation satisfied the specifications for high-temperature and high-pressure characteristics, acid resistance, calcium chloride resistance, and appearance. In particular, it can be seen that the high temperature and high pressure characteristics are improved as compared with Example 10.

100 Intercooler 111 Tube 120 Header tank 121 Core plate 122 Tank body (resin parts)

Claims (11)

In a heat exchanger for an intercooler comprising resin parts made of glass fiber reinforced resin material,
When the longest width in the cross section of the glass fiber is the major axis, the longest width in the direction perpendicular to the major axis direction is the minor axis, and the ratio of the major axis to the minor axis is the profile ratio,
The resin component is composed of a resin composition containing 1 to 250 parts by weight of glass fiber (B) having an average value of the deformed ratio larger than 1 with respect to 100 parts by weight of the thermoplastic resin (A). A heat exchanger for an intercooler characterized by being made.   The said glass fiber (B) is the heat exchanger for intercoolers of Claim 1 whose average value of the said deformed ratio is 1.5-6.   The thermoplastic resin (A) contains 30 to 100 parts by weight of polyamide (a1) in 100 parts by weight of the total amount of the thermoplastic resin (A). Heat exchanger for intercooler. The polyamide (a1) has a dicarboxylic acid unit (i) and a diamine unit (ii),
The dicarboxylic acid unit (i) comprises 40 to 100 mol% of terephthalic acid units, 0 to 40 mol% of aromatic dicarboxylic acid units other than terephthalic acid, and 0 to 60 mol% of aliphatic dicarboxylic acid units. So that their total is 100 mol%,
The said diamine unit (ii) contains 60-100 mol% of C4-C18 aliphatic diamine units, The heat exchanger for intercoolers of Claim 3 characterized by the above-mentioned.   5. The inter of claim 4, wherein both 1,9-nonanediamine unit and 2-methyl-1,8-octanediamine unit are used as the aliphatic diamine unit having 4 to 18 carbon atoms. Heat exchanger for cooler.   6. The polyamide (a1) having an intrinsic viscosity of 0.4 to 3.0 dl / g measured at 30 ° C. in concentrated sulfuric acid is used. The heat exchanger for intercoolers as described in one.   The heat exchanger for intercoolers according to claim 1 or 2, wherein polyphenylene sulfide (a2) is used as said thermoplastic resin (A). As the thermoplastic resin (A), a modified resin (a3) is used,
The heat modified by the modified resin (a3) by at least one resin selected from the group consisting of polyolefin resins, polyester resins, polythioether resins, polyacrylonitrile resins, fluorine resins and styrene elastomers. The heat exchanger for intercoolers according to claim 1 or 2, wherein the heat exchanger is a plastic resin. A plurality of tubes (111) through which fluid flows;
A header tank (120) disposed at both longitudinal ends of the tube (111), extending in a direction perpendicular to the longitudinal direction of the tube (111) and communicating with the plurality of tubes (111);
The header tank (120) includes a core plate (123) to which the plurality of tubes (111) are joined, and a tank body (125) that forms a tank internal space together with the core plate (123). And
The heat exchanger for an intercooler according to any one of claims 1 to 8, wherein the resin component is the tank body (122). The fluid is a mixed gas of combustion air sucked into the internal combustion engine and exhaust gas recirculated to the internal combustion engine,
The heat exchanger for intercoolers according to claim 9, wherein the heat exchanger is used as an intercooler for cooling the mixed gas. The resin composition contains 70 to 150 parts by weight of the glass fiber (B) with respect to 100 parts by weight of the thermoplastic resin (A). The heat exchanger for an intercooler as described.

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